Information on industrial burners - ESIWeishaupt WK series industrial burners are of modular design. That means the fan, control panel, pump assembly and preheater station are all

productInformation on industrial burners

Industrial burner WKIndustrial burners WK40 to WK80 • 300 kW to 22,000 kW

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A powerful industrial burnerof modular constructionWeishaupt WK series industrial burners have been especially designed for industrial use. The modular design principle enablesthese burners to be matched to numerous special applications. Alarge capacity range supports thewide spectrum of applications.

Modular principleWeishaupt WK series industrial burnersare of modular design. That means thefan, control panel, pump assembly andpreheater station are all matched independently of the burner. This concept offers a high degree of flexibility in matching with numerous application requirements.

Digital combustion managementUsing digital combustion managementensures simple and reliable operation ofa combustion plant. All important functions such as fuel and air supply,flame monitoring, etc, are controlledwith digital precision. Operational functions are optimised, economy is maximised, and emissions are reducedto a minimum.

New mixing headThe newly developed mixing head hasgreatly reduced burner pressure losses.Operational vibrations have been reduced, as have NOx emissions — considerably so in some cases.

Insulated burner housingThe burner housing is fitted with internalinsulation as standard. This significantlyreduces the surface temperature of thehousing during operation with preheated combustion air. The insulation also provides effectivenoise reduction, with noise levels below 85 dB(A).

Nozzle head shut off deviceAt burner shutdown or when changingover to gas operation, a safety shut offdevice located in the oil atomising system shuts off the oil flow directly inthe nozzle orifice. Oil cannot escapefrom the nozzle head. However, onheavy oil burners it is possible for preheated oil to flow through the nozzleduring the heat up phase. This ensurethat oil with the correct viscosity is available immediately for flame formation.By using the type tested nozzle headshut off device the high operationalavailability of the burner is further increased.

Modulating controlThe modulating burners operate according to the current heat demand atany point within the control range.

Reduced capacity at start upA gas ignition device enables gas firingburners to start operation at a reducedignition load. This means that only asmall quantity of gas flows into the combustion chamber. After a short delay the burner drives to partial load.

Controlled shutdown from partialloadControlled shutdown of the burner always takes place from the partial loadposition, thus preventing impact on thegas main.

Heat recovery using preheated combustion airMany industrial processes create highflue gas temperatures due to the hightemperature of the medium used. A large amount of energy can be reclaimed from these hot flue gases,which is returned via a heat exchangerin the flue. Efficiency can be increasedby up to 9% using this technology. Weishaupt WK series industrial burnerscan be operated with combustion airtemperatures of up to 250° C.

Valve trainsTo comply with EN 676 burners must beequipped with two safety shut off valves.Weishaupt gas and dual fuel burnersare equipped with Class A double gasvalves as standard. The W-FM100/200combustion manager provides for gasvalve proving as standard. The requiredgas pressure switch is included in thedelivery. Other gas side accessoriessuch as gas filters and gas pressure regulators can be found in the list ofaccessories.

Simple maintenanceUpon removing the housing’s cover thediffuser, nozzle, ignition electrodes andmixing head are readily accessible. After removing the mixing head, theflame tube can simply be withdrawnthrough the opening in the housing. Thecomponents for the regulation of gas, oiland air are neatly arranged in the controls assembly and are easily accessible. This simplifies all maintenance work.

FuelsFuel oil EL (< 6 mm2/s at 20° C) to DIN 51 603, T1Fuel oil S (< 50 mm2/s at 100° C)to DIN 51 603, T3 and T5Natural Gas ENatural Gas LLLiquid Petroleum Gas B/P

ApplicationsThe burners can be used with heat exchangers such as hot water boilers,steam boilers, air heaters and for certainprocess applications. The combustionair must be free of aggressive substances (Halogens, Chloride, Fluoride, etc) and impurities (dust, debris, moisture, etc). Oil and gas instal-lations must comply with prevailingstandards.

Permissible ambient conditions• Ambient temperature -15 to +40°C (in operation)• Humidity: ≤ 80% relative humidity, no dew point

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• Suitable for indoor operation only• For plant in unheated areas certain

further measures may be required(please enquire)

Use of the burner for applications or inambient conditions not detailed above isnot permitted without the prior writtenagreement of Max Weishaupt GmbH.The service intervals will be reduced inaccordance with the more extreme operational conditions.

Type test certificationThe burners sizes 70 and 80 have beentype tested by an independent body andconform to the following standards andEU Directives:

• EN 267 and EN 676• Pressure Vessel Directive 97/23/EC• Gas Appliance Directive 2009/142/EC• Machinery Directive 2006/42/EC• Electromagnetic Compatibility 2004/108/EC• Low Voltage Directive 2006/95/EC• The burners carry the CE mark and a

CE-PIN No. and are voluntarily DIN registered.

To meet the NOx limit values certain requirements regarding minimum combustion chamber dimension mustbe observed.

Outstanding serviceWeishaupt maintains an extensiveglobal sales and service network. Customer service is available every dayaround the clock. In-house training byWeishaupt ensures the high standard oftheir service engineers.

A number of variation are availableto meet the different emission requirements:

Version ZM (Standard) Oil, gas and dual fuel burners for installations without specific NOx requirements. Suitable for Natural Gas,Liquid Petroleum Gas, distillate oil, residual oil, as well as special gases andspecial oils on request. Type tested burners for Natural Gas and distillate oilin vers. ZM (cold air) comply with NOxClass 1 to EN 676 and EN 267.

Version NR Gas and dual fuel burners with advanced, standard mixing head for installations with gas side NOxrequirements. NR means: lower gas side NOx values compared to the standardversion. Oil side as standard version.Suitable for Natural Gas, Liquid Petroleum Gas, distillate oil, residual oil.Type tested burners for Natural Gas,Liquid Petroleum Gas and distillate oil invers. ZM-NR (cold air) comply with NOxClass 2 (in some cases even NOx Class3) on the gas side and NOx Class 1 toEN 676 and EN 267 on the oil side.

Version 1LN LowNOx gas and dual fuel burners withspecial mixing head for installations withgas and oil side NOx requirements. 1LN means: lower NOx values compared to version NR. Suitable forNatural Gas, Liquid Petroleum Gas, distillate oil. Type tested burners for Natural Gas, Liquid Petroleum Gas anddistillate oil in vers. ZM-1LN (cold air)comply with NOx Class 3 on the gasside and NOx Class 2 to EN 676 and EN 267 on the oil side.

Version LN LowNOx gas burners with special mixing head for installations with gasside NOx requirements. LN means: lower gas side NOx value compared tovers. 1LN. Suitable for Natural Gas andLiquid Petroleum Gas. Type testedburners for Natural Gas in vers. ZM-LN(cold air) comply with NOx Class 3 toEN 676.

Version 3LN LowNOx gas and dual fuel burners withmultiflam mixing head for installationswith extremely low NOx requirements(only for boilers of the three pass orburn-through principle). Extremely lowNOx values achieved by fuel division.Suitable for Natural Gas, Liquid Petroleum Gas and distillate oil. Typetested burners for Natural Gas in vers. ZM-3LN (cold air) comply withNOx Class 3 to EN 676 and EN 267.

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Digital Combustion management:Precise, simple and reliable

Digital combustion managementmeans optimal combustion figures,continually reproducible setting figures and ease of use.

Weishaupt WK series burners areequipped as standard with electroniccompound regulation and digital combustion management. Modern combustion technologies demand aprecise, continually reproducible mixingof fuel and combustion air. Only in thisway can optimum combustion figuresbe ensured over extended periods.

Simple operationSetting and control of the burner isachieved using the ABE display and operating unit. The unit, which is linkedto the combustion manager via a bus system, presents clear text messages in a choice of languages, enabling theuser friendly setting of the burner.

Flexible communication possibilitiesThe integral interface enables all necessary information and functions tobe relayed to superordinate control systems. If required, a modem enables atelephone connection to be installed forremote operation, monitoring and diagnosis.

Bus communication with customersystems / BMS systemsBurner data can be exchanged with aPLC system or integrated into a BMSsystem. Converters are available, whichallow data transfer from the internal burner bus technology to various common Bus systems.

New technology advantagesDigital combustion management makesburner operation simple and reliable.

The most important advantages at aglance:

• One unit for all burner variations• Optimum combustion values achieved by precise control • Integrated valve proving

(gas operation)• Integrated load controller• Separate display and operating unit for increased convenience• Clear text display for simple operation• Available in a number of different languages• Flexible communication possibilities are offered by various types of interface

Other advantages:

• No additional burner controls are necessary as control is effected by the combustion manager.

• Reduced installation expense: Each burner is tested and supplied by

the factory as a complete unit.• Commissioning and service work

takes less time. The burner’s basic parameters are set at the factory. Adjustment to site conditions and combustion emission checks are effected via the combustion manager’s menu controlled commissioning program.

Setting and control of the burner via the ABE display and operating unit

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Example diagram with W-FM 200

Remote control and communications modem W-FKM

Remote control via landline or mobilephone line

System networking viaPLC / DDC

Visualisation viaPC / Touch Panel

Mod

bus

CA

N-B

us

Burner with inbuilt digital combustion management

W-FM 200combustion manager

Gas supply

Display andoperating unit

O2 module

O2 sensor

Oil supply

Air supply

Regulating sleeve

Freq

uenc

y co

nver

ter

for s

peed

con

trol

M

6

Gas valve train and accessories

Accessories for oil supply

Fan for burner and cooling air

Components supplied by others

System technology from one sourceensures reliability

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Burner type Version Fuel Capacity kW ZMH / ZM

WK 40/1 ZM Dist. oil 450 – 1800 / 2200 Res. oil 550 – 1800 / 2200







Selection and design of the fan, gas valve trains, special equipment as well as technical data and dimensions see planning document.

Distillate and residual oil burners WKL and WKMS

Version ZM

Capacity overviewOil burners

0 2,000 4,000 6,000 8,000 10,000 12,000 14,000 16,000 18,000 20,000 22,000

Version ZM: Combustion air temperature up to 20° CVersion ZM-H: Combustion air temperature up to 250° C

Capacity overviewGas burners

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WK 40/1 ZM Nat. Gas 300 – 1800 / 2200 LPG 300 – 1800 / 2200

WK 40/2 ZM Nat. Gas 400 – 2500 / 3000 LPG 400 – 2500 / 3000

WK 50/1 ZM Nat. Gas 600 – 3200 / 4000 LPG 600 – 3200 / 4000

WK 50/2 ZM Nat. Gas 800 – 5000 / 6000 LPG 800 – 5000 / 6000

WK 70/1 ZM Nat. Gas 1100 – 5600 / 7000

Natural Gas and Liquid Petroleum Gas burners WKG

0 2,000 4,000 6,000 8,000 10,000 12,000 14,000 16,000 18,000 20,000 22,000



WK 50/1 NR Nat. Gas 600 – 3200 / 4000 LPG 600 – 3200 / 4000

WK 50/2 NR Nat. Gas 800 – 5000 / 6000 LPG 800 – 5000 / 6000

WK 70/1 NR Nat. Gas 1100 – 5600 / 7000 LPG 1100 – 5600 / 7000

WK 70/3 NR Nat. Gas 1400 – 9600 / 12000 LPG 2000 – 9600 / 12000

WK 80/3 NR Nat. Gas 2200 – 17600 / 22000 LPG 3200 – 17600 / 22000


0 2,000 4,000 6,000 8,000 10,000 12,000 14,000 16,000 18,000 20,000 22,000

Version ZM

Version NR


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WK 50/1 1LN Nat. Gas 600 – 3000 / 3600 LPG 600 – 3000 / 3600

WK 50/2 1LN Nat. Gas 800 – 4800 / 5500 LPG 950 – 4800 / 5500

WK 70/1 1LN Nat. Gas 1000 – 5600 / 7000 LPG 1200 – 5600 / 7000

WK 70/2 1LN Nat. Gas 1100 – 9600 / 12000 LPG 1400 – 9600 / 12000


0 2,000 4,000 6,000 8,000 10,000 12,000 14,000 16,000 18,000 20,000 22,000


Version 1LN



WK 40/2 LN Nat. Gas 500 – 2500 / 3000

WK 70/1 LN Nat. Gas 1200 – 5600 / 7000

WK 70/2 LN Nat. Gas 1750 – 8800 / 11000

Natural Gas burners WKG

0 2,000 4,000 6,000 8,000 10,000 12,000 14,000 16,000 18,000 20,000 22,000

Version LN

Capacity overviewDual fuel burners

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WK 40/1 ZM Nat. Gas 300 – 1800 / 2200 LPG 300 – 1800 / 2200 Dist. oil 450 – 1800 / 2200 Res. oil 550 – 1800 / 2200




WK 70/1 ZM Nat. Gas 1100 – 5600 / 7000 Dist. oil 1200 – 5600 / 7000 Res. oil 1800 – 5600 / 7000

Dual fuel burners WKGL and WKGMS

0 2,000 4,000 6,000 8,000 10,000 12,000 14,000 16,000 18,000 20,000 22,000

Version ZM



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WK 50/1 1LN Nat. Gas 600 – 3000 / 3600 LPG 600 – 3000 / 3600 Dist. oil 800 – 3000 / 3600




Dual fuel burner WKGL

0 2,000 4,000 6,000 8,000 10,000 12,000 14,000 16,000 18,000 20,000 22,000


Version 1LN


WK 50/1 NR Nat. Gas 600 – 3200 / 4000 LPG 600 – 3200 / 4000 Dist. oil 712 – 3200 / 4000 Res. oil 1000 – 3200 / 4000





Dual fuel burners WKGL and WKGMS

0 2,000 4,000 6,000 8,000 10,000 12,000 14,000 16,000 18,000 20,000 22,000

Version NR


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10

20

30

40

50

60

70

80

90

100

110

120

130

140

150

160

170

180

190

200

The multiflam® principle:Emission reduction as standard

Example values for warm water plant are dependent on the combustion chamber

The multiflam® flame shows efficient combustion

In 1998, Weishaupt made history withthe market introduction of multiflam®technology. Unprecedented low emissions stunned the industry. Withthe patented mixing head, Weishauptwas able to reduce the Nitrous Oxide emissions (NOx) of medium and largeburners to those of compact burners.With values below 120 mg/kWh for oiland 80 mg/kWh for gas, dependent on the combustion chamber geometry,Weishaupt set new standards.

The multiflam® burners meet the moststringent worldwide regulations and aretherefore leaders among industrial burners, particularly in countries withstrict environmental regulations such asSwitzerland.

The core of multiflam® technology is thespecial design of the mixing head inwhich the fuel is divided and the energyis released by secondary and primary flames, more environmentally friendlythan ever before. This is achieved by therecirculation of the combustion mixture directly at the mixing head.

Schematic representation of the mixing head

Secondary nozzle 1

Primary nozzle 2

Primary nozzle

Primary air

Secondary nozzle 4

Secondary air

Secondary nozzle 3

Primary diffuser

Secondary diffuser

mg/m3

10

20

30

40

50

60

70

80

90

100

110

120

130

140

150

160

170

180

190

200

mg/m3

Gas Oil

TA Luft Gas / 1. BImschV

10 to 20 MW

LRV Gas

TA Luft Oil/1. BImschV

10 to 20 MW

LRV Oil

CO

CO

NO

x

NO

x

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Burner type Version Fuel Capacity kW

WK 70/1* 3LN Dist. oil 1550 – 10000

WK 70/2* 3LN Dist. oil 1800 – 12000

WK 70/3* 3LN Dist. oil 1800 – 13000

WK 80/1* 3LN Dist. oil 2380 – 17000

* Burner sizes WK 70 and WK 80 in version 3LN multiflam are not available as oil only burners. However, the dual fuel burner WKGL in version ”without gas valve train and gas accessories“ can be used. Reduced price see price list.

Distillate oil burners WKGL0 2,000 4,000 6,000 8,000 10,000 12,000 14,000 16,000 18,000 20,000 22,000


WK 70/1 3LN Nat. Gas 1000 – 10000

WK 70/2 3LN Nat. Gas 1100 – 12000

WK 70/3 * 3LN Nat. Gas 1100 – 13000

WK 80/1 3LN Nat. Gas 1800 – 17000

* Burner size WK 70/3 in version 3LN is not available as a gas only burner. However, the dual fuel burner WKGL in version ”without oil pump” can be used. Reduced price see price list.

Natural gas burners WKG and WKGL

0 2,000 4,000 6,000 8,000 10,000 12,000 14,000 16,000 18,000 20,000 22,000


WK 70/1 3LN Nat. Gas 1000 – 10000 Dist. oil 1550 – 10000


WK 70/3 3LN Nat. Gas 1100 – 13000 Leichtöl 1800 – 13000


Dual fuel burners WKGL

0 2,000 4,000 6,000 8,000 10,000 12,000 14,000 16,000 18,000 20,000 22,000

Distillate oil burners version 3LN multiflam®

Natural Gas burners version 3LN multiflam®

Dual fuel burners version 3LN multiflam®


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Fuel systemsOil burners

1 Oil pump2 Oil preheater3 Strainer4 Supply temperature sensor 5 Return temperature sensor6 Min. pressure switch7 Max. pressure switch8 Supply solenoid valve (fitted in flow direction)9 Return solenoid valve (fitted against the flow direction)10 Bypass solenoid valve (normally open)11 Solenoid nozzle head12 Oil quantity regulator

1

3

9

P

P

MM 7 12 11

6 8

M

115V

115V

WKL40 pump fitted

P

P ϑ

ϑ

MM

M

2

3

Pϑ

64 10

115V

230V

115V

8

115V

1

M

9

P

7 12

M115V

ϑ

5 11

WKMS40 pump and preheater fitted

1

3

9

P

P

MM 7 12 11

6 8

M115V

115V

WKL70 and WKL80

P

P ϑ

ϑ

M

MM

2 3 64 10 82 3

P

P

ϑ

64 10

M

0V23

5V11

ϑ

8

M

5V11

1

M 9 7 12 5 1112

WKMS70 and WKMS80

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Layout of the valve trainOn boilers with hinged doors, the valve train must be mounted onthe opposite side to the boiler door hinges.

CompensatorTo enable tension free mounting of the valve train, the fitting of a compensator is recommended.

Break points in the gas valve trainBreak points in the valve train should be provided to enable thedoor of the heat exchanger to be swung open. The main gas lineis best separated at the compensator.

Oil burners version 3LN multiflam®

10

3 3 7

9 8

115V 115V

115V 115V

P

P

6 5

2 2 4

M

1

MM

WKL

1 External pump station with pressurisation2 Supply solenoid valve (fitted in flow direction)3 Return solenoid valve (fitted against flow direction)4 Nozzle head with Simplex nozzle and inbuilt shut off valve (primary nozzle)5 Nozzle head HDK30 or HDK40 with return flow nozzle (secondary nozzles)6 Oil regulator7 Oil pressure switch for return pressure8 Oil pressure switch for supply pressure9 Strainer10 Filter (30 bar, mesh aperture: 0.1 mm) fitted close to the burner

Supporting the valve train assemblyThe valve train should be properly supported in accordance withthe site conditions. See Weishaupt accessories list for variousvalve train support components.

Gas meterA gas meter must be installed to measure gas consumption during commissioning.

Thermal shut off device (TAE)optional depending on regulationsIntegrated into the ball valve on screwed valve trains. Separate component with HTB seals in front of ball valve for flanged valvetrains.

Gas burners

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1 2 3 4 5 6 7 8

10 11

PP P

With gas butterfly valve and valve proving

1 Isolating valve2 Gas filter3 Pressure regulator4 High gas pressure switch (with TRD)5 Low gas pressure switch6 Valve proving W-FM100 / W-FM2007 Double gas valve8 Gas butterfly valve9 Pressure gauge with push button valve10 Ignition gas solenoid valve (not with version LN)11 Burner

We’re right where you need usA strong service network givespeace of mindWeishaupt equipment is available fromgood heating companies, with whomWeishaupt works in partnership. To support the specialists, Weishauptmaintains a large sales and service network. Delivery, spares and serviceare thus continually ensured.

Even in an emergency, Weishaupt is oncall. The service department is available to Weishaupt customers around the clock, 365 days a year. AWeishaupt branch office or agency nearyou can answer all your questions onheating and Weishaupt burners.

Max Weis haupt GmbHD-88475 Schwen diTe l. + 49 73 53 8 30, Fax + 49 73 53 8 33 58www.weis haupt.de

Print No. 83159802, January 2011Printed in Germany. All rights reserved.

Weishaupt (UK) LimitedNeachells Lane, Willenhall, WV13 3RGTel (01902) 609841, Fax (01902) 633343www.weishaupt.co.uk

Documents

Information on industrial burners - ESIWeishaupt WK series industrial burners are of modular design. That means the fan, control panel, pump assembly and preheater station are all